Vehicle seat headrest

ABSTRACT

The object of the present invention is to provide a headrest capable of, when a user touches the headrest, preventing the user&#39;s finger from being inserted into the inner space of the headrest. The vehicle seat headrest according to the present invention includes: a stay (402) held on the seat back side; and a headrest main body (4A) supported forward rotatably from a using position with respect to the stay (402). The headrest main body (4A) has: a main body frame (401) forming a strength member; hinge parts (403a), (403b) which connect the main body frame (401) rotatably with respect to the stay (402); a locking mechanism (500) which fixes the main body frame (401) in the using position with respect to the stay (402); and cushion material (407) which covers the main body frame (401) and the hinge parts (403a), (403b). In the vehicle seat headrest, a resin lower cover (408), having an opening (408a) through which the stay (402) is inserted, covers a lower surface of the headrest main body (4A).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. national phase application filed under 35 U.S.C. § 371 of International Application No. PCT/JP2016/062396, filed Apr. 19, 2016, designating the United States, which claims priority from Japanese Patent Application No. 2015-088211, filed Apr. 23, 2015, which are hereby incorporated herein by reference in their entirety.

TECHNICAL FIELD

The present invention relates to a headrest for a vehicle seat which is used in a vehicle and on which an occupant is seated.

BACKGROUND ART

In some vehicle seats, a forward tiltable headrest which is forward tiltable from a using position by releasing a locking function is used. A headrest described in Japanese Patent Application Laid-Open No. 2006-87702 (Patent Literature 1) is known as this type of headrest.

The Patent Literature 1 describes a vehicle seat device having a locking mechanism to fix a headrest mounted to the top of a seat back in a using position, and an unlocking mechanism to release the locked state with the locking mechanism. The locking mechanism has a locking plate attached to a rotary shaft of the headrest and an engaging hook engaged with the locking plate. The unlocking mechanism has an operation rod which protrudes from the top of the seat back toward the head rest (see the Abstract). Further, the Patent Literature 1 describes a configuration where the perimeter of the insert stay provided as a core body of the headrest is covered with a cushion body formed with a pad body of urethane foam or the like and skin material (see paragraph 0012).

CITATION LIST Patent Literature

PTL 1: Japanese Patent Application Laid-Open No. 2006-87702

SUMMARY OF INVENTION Technical Problem

The patent Literature 1 has no sufficient description of the configuration of the lower end side of the headrest. The cushion body generally covers the headrest downward from the top. Accordingly, an opening is formed on the lower end side of the headrest. The stay to hold the headrest on the seat back side protrudes downward from the opening. With this opening, when the headrest is tilted, the tilting operation is possible without interference between the stay and the cushion body.

The locking mechanism is accommodated in the inner space of the headrest covered with the cushion body. Upon tilting of the headrest, there is a possibility that a user touches the headrest and the user's finger enters the inner space, accommodating the locking mechanism, from the opening of the cushion body.

The object of the present invention is to provide a headrest capable of, when a user touches the headrest, preventing the user's finger from being inserted into the inner space of the headrest.

Solution to Problem

To attain the above-described object, provides is a vehicle seat headrest including a stay held on the seat back side, and a headrest main body supported forward rotatably from a using position with respect to the stay. The headrest main body has a main body frame forming a strength member, a hinge part which connects the main body frame rotatably with respect to the stay, a locking mechanism which fixes the main body frame in the using position with respect to the stay, and cushion material which covers the main body frame and the hinge part. A resin lower cover, having an opening through which the stay is inserted, covers a lower surface of the headrest main body.

Advantageous Effects of Invention

According to the present invention, it is possible to provide a headrest capable of, when a user touches the headrest, preventing the user's finger from being inserted into the inner space of the headrest.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a vehicle seat according to an embodiment of the present invention.

FIG. 2 is a plan view (front view) of a headrest according to the embodiment of the present invention viewed from the front.

FIG. 3 is a plan view (side view) of the headrest according to the embodiment of the present invention viewed from the side.

FIG. 4 is a plan view showing a structure of a right hinge part (locked state) of the headrest according to the embodiment of the present invention.

FIG. 5 is a plan view showing the structure of the right hinge part (unlocked state) of the headrest according to the embodiment of the present invention.

FIG. 6 is a plan view showing a structure of a left hinge part (locked time) of the headrest according to the embodiment of the present invention.

FIG. 7 is a perspective view showing a mechanism assembly formed by assembling a main body frame, a stay, the hinge parts, a rotary shaft, a connecting part and a biasing member, regarding the headrest according to the embodiment of the present invention.

FIG. 8 is an exploded perspective view showing the headrest in exploded state according to the embodiment of the present invention.

FIG. 9 is a perspective view showing a lower cover.

FIG. 10 is a perspective view showing a status where the lower cover is assembled to the mechanism assembly.

FIG. 11 is a perspective view of the left hinge part viewed from the front side.

FIG. 12 is a cross-sectional view showing an assembled status of the lower cover and skin material.

FIG. 13 is a perspective view of the headrest as a comparative example with respect to the present invention viewed from the lower surface side.

DESCRIPTION OF EMBODIMENTS

Hereinbelow, an embodiment according to the present invention will be described.

FIG. 1 is a perspective view of a vehicle seat according to the embodiment of the present invention.

As shown in FIG. 1, a vehicle seat 1 has a seat cushion 2 on which a person is seated, a seat back 3 which is provided upright at a rear end of the seat cushion, and a headrest 4 provided at an upper end of the seat back 3. The seat cushion 2 is attached, in a status where its position is adjustable in a longitudinal direction, to the floor of the vehicle. The seat back 3 is connected, in a rotatable status about a rotary shaft 3A provided at the lower end, to the seat cushion 2. The headrest 4 is attached, in a height-position adjustable state, to the seat back 3. A frame as a structural member, and cushion material such as resin foam, are provided inside the seat cushion 2, the seat back 3, and the headrest 4. The surface of the cushion material is covered with a cover. Note that in FIG. 1, the cushion material and the rotary shaft 3A covered with a cover are indicated with an alternate long and short dash line.

FIG. 2 is a plan view (front view) of the headrest according to the embodiment of the present invention viewed from the front. FIG. 3 is a plan view (side view) of the headrest according to the embodiment of the present invention viewed from the side. Note that FIG. 2 is a diagram viewed from an arrow II direction in FIG. 3. FIG. 3 is a diagram viewed from an arrow III direction in FIG. 2. FIG. 2 and FIG. 3 represent a main body frame 401 and the like which are provided inside and seen through an exterior covering. Further, FIG. 2 represents the headrest in a partially-cutaway state.

The headrest 4 has a main body frame 401, a stay 402, a hinge part 403, a rotary shaft (tiltable shaft) 404, a connecting part 405, a biasing member 406, cushion material 407, a lower cover (bottom cover) 408, skin 409, and an operation strap 410.

The main body frame 401 is a strength member as a skeletal structure of a headrest main body 4A and is made of metal. The main body frame 401 has a right frame part 401 a, a left frame part 401 b, and a connecting frame part 401 c connecting the right frame part 401 a to the left frame part 401 b. An extension part 401 d bent toward the inside of the headrest 4 is provided at a lower end of the right frame part 401 a.

The right frame part 401 a is a frame part provided on the right side of the vehicle seat 1 in the width direction and extended in the vertical direction. The left frame part 401 b is a frame part provided on the left side of the vehicle seat 1 in the width direction and extended in the vertical direction. The right frame part 401 a and the left frame part 401 b are extended in the vertical direction, however, they may be not only extended but tilted from the vertical direction.

The connecting frame part 401 c is a frame part which connects the right frame part 401 a to the left frame part 401 b. The connecting frame part 401 c connects the upper end side of the right frame part 401 a to the upper end side of the left frame part 401 b. The respective connecting parts draw a curve.

The main body frame 401 has an approximately quadrangle shape (approximately rectangular shape), in which each corner is made of a curve, with the right frame part 401 a, the left frame part 401 b, the connecting frame part 401 c and the extension part 401 d. The right frame part 401 a, the left frame part 401 b, the connecting frame part 401 c, and the extension part 401 d respectively have a linear portion.

The linear portion of the right frame part 401 a and the linear portion of the left frame part 401 b are parallel to each other. The linear portion of the connecting frame part 401 c forms a 90 degree angle (right angle) with respect to the linear portion of the right frame part 401 a and the linear portion of the left frame part 401 b. The linear portion of the extension part 401 d is parallel to the linear portion of the connecting frame part 401 c, and forms a 90 degree angle (right angle) with respect to the linear portion of the right frame part 401 a.

The stay 402 is a member which protrudes downward from the main body 4A of the headrest 4, and supports the main body 4A on the seat back 3, as a mainstay. The stay 402 has a right stay part 402 a, a left stay part 402 b, and a connecting stay part 402 c which connects the right stay part 402 a to the left stay part 402 b. The connecting stay part 402 c connects the upper end side of the right stay part 402 a to the upper end side of the left stay part 402 b. The respective connecting parts draw a curve.

The stay 402 is formed in an inverse U shape with the right stay part 402 a, the left stay part 402 b and the connecting stay part 402 c. The right stay part 402 a, the left stay part 402 b, and the connecting stay part 402 c respectively have a linear portion. The linear portion of the right stay part 402 a and the linear portion of the left stay part 402 b are parallel to each other. The linear portion of the connecting stay part 402 c forms a 90 degree angle (right angle) with respect to the linear portion of the right stay part 402 a and the linear portion of the left stay part 402 b.

Note that the linear portion of the connecting stay part 402 c is provided in a position lower than the lower end of the main body frame 401. That is, the extension part 401 d formed at the lower end of the right frame part 401 a is positioned in a higher position than (above) the linear portion of the connecting stay part 402 c.

As indicated with an alternate long and short dash line 402 d in FIG. 3, the left stay part 402 b is bent at an upper end 403 e of the linear portion. Further, the right stay part 402 a is bent at an upper end of the linear portion as in the case of the left stay part 402 b. As the right stay part 402 a and the left stay part 402 b are respectively provided with a bent portion 403 e, the connecting stay part 402 c is provided over the upper side of the rotary shaft 404.

The hinge part 403 is provided at a lower end of the main body frame 401. The hinge part 403 has a right hinge part 403 a provided at a lower end of the right frame part 401 a and a left hinge part 403 b provided at a lower end of the left frame part 401 b. The hinge part 403 will be described in detail later.

The rotary shaft (tiltable shaft) 404 is connected to the right hinge part 403 a and the left hinge part 403 b. However, the rotary shaft (tiltable shaft) 404 is not fixed with respect to the right hinge part 403 a and the left hinge part 403 b. That is, the right hinge part 403 a and the left hinge part 403 b are connected with respect to the rotary shaft 404 rotatably about the rotary shaft 404.

The rotary shaft 404 is a straight-line bar-type member. In the present embodiment, a round bar member having a hollow circular cross section is used. The rotary shaft 404 is parallel to the linear portion of the connecting stay part 402 c and the linear portion of the connecting frame part 401 c.

Further, the rotary shaft 404 is provided in a position lower than the linear portion of the connecting stay part 402 c. That is, the rotary shaft 404 is provided below the linear portion of the connecting stay part 402 c.

The connecting part 405 is a member which connects the rotary shaft 404 to the linear portion of the connecting stay part 402 c. The connecting part 405 has a right connecting part 405 a and a left connecting part 405 b positioned at both ends of the linear portion of the connecting stay part 402 c. The rotary shaft 404 and the connecting stay part 402 c are fixed with the both connecting parts 405 a and 405 b.

The biasing member 406 is a member which is provided between the rotary shaft 404 and the main body frame 401, and which pushes the main body frame 401 forward. The biasing member 406 is formed with a coil spring. It is fitted around the rotary shaft 404. That is, the coil spring 406 is attached to the rotary shaft 404 such that the rotary shaft 404 is inserted through the center of the coil spring 406. One end of the coil spring 406 is latched on the right connecting part 405 a. The other end of the coil spring 406 is latched on the extension part 401 d of the main body frame 401.

The extension part 401 d of the main body frame 401 forms a latch part of the coil spring 406. As the latch part, not only the extension part 401 d of the main body frame 401 but any member may be used as long as the other end of the coil spring 406 is latched on the main body frame 401 side. Further, not only the right connecting part 405 a but any part may be used as long as the one end of the coil spring 406 is latched on the stay 402 side. With this configuration, the coil spring 406 pushes the headrest main body 4A such that the headrest main body 4A is tilted forward. In FIG. 3, the status where the headrest main body 4A is tilted forward is indicated with reference numeral 4A′.

The cushion material 407 is provided so as to cover the entire periphery of the main body frame 401, the hinge part 403, the rotary shaft 404, the connecting part 405 and the biasing member 406. Further, the cushion material 407 covers an upper end of the stay 402.

The lower cover (bottom cover) 408 is attached to an opening formed at a lower end of the cushion material 407. The lower cover 408 will be described in detail later.

The skin 409 covers an external surface of the cushion material. The skin 409 may be provided so as to cover the outer periphery of the lower cover 408.

The operation strap 410 is used for releasing operation for a locking mechanism 500 (see FIG. 4). It is possible to tilt the headrest main body 4A forward by releasing the locking mechanism 500.

Next, the hinge part 403 will be described using FIG. 4 to FIG. 6. The headrest according to the present embodiment has the stay 402 held on the seat back side, and the headrest main body 4A supported forward rotatably from a using position with respect to the stay 402. The hinge part 403 is a member which connects the main body frame 401 of the headrest main body 4A rotatably with respect to the stay 402.

FIG. 4 is a plan view showing the structure of the right hinge part (locked state) of the headrest according to the embodiment of the present invention.

The locking mechanism 500 is provided on the back surface of the left hinge part 403 b. The locking mechanism 500 has a rotary plate 501, an engagement hook 502, an engagement hook biasing spring 503, an operation lever 504, and an operation lever biasing spring 505.

The rotary plate (rocking plate) 501 is fixed to the rotary shaft 404. The rotary plate 501 rocks (rotates) about the rotary shaft (rocking shaft) 404 with respect to the left hinge part 403 b upon tilting of the headrest main body 4A. Otherwise, upon tilting of the headrest main body 4A, the left hinge part 403 b rocks with respect to the rotary plate 501.

The rocking of the left hinge part 403 b and the rotary plate 501 are relative. Actually, as the rotary plate 501 is on the fixed side, the left hinge part 403 b rocks with respect to the rotary plate 501.

The rotary plate 501 is provided with an engagement groove 501 a and a sliding surface 501 b. The engagement groove 501 a forms an engagement part with which the engagement hook 502 is engaged. As the engagement hook 502 is engaged with the engagement groove 501 a, the locking mechanism 500 enters a locked state. The sliding surface 501 b is a curved surface on which the engagement hook 502 disengaged from the engagement groove 501 a slides when the headrest main body 4A is tilted toward a front direction F or returned from a tilted position to the using position. In the present embodiment, the sliding surface 501 b is a circular arc-shaped surface around the center of the rotary shaft 404.

The rotary plate 501 is provided with a protruding portion 501 c in contact with an edge 403 ba of the left hinge part 403 b. In normal time, a gap exists between the protruding portion 501 c and the edge 403 ba, and the protruding portion 501 c and the edge 403 b a are not in contact with each other. When a strong force acts on the headrest main body 4A, the protruding portion 501 c and the edge 403 ba are mutually in contact with each other, to receive the force acting on the headrest main body 4A. With this configuration, it is possible to prevent the headrest main body 4A from tilting toward the rear side (backward tilting).

In the engagement groove 501 a of the rotary plate 501, the height of a side surface 501 aa is higher than the height of a side surface 501 ab. This relation is set such that when the headrest main body 4A is returned from the tilted position to the using position, the engagement claw 502 a of the engagement hook 502 slides on the sliding surface 501 b while it is infallibly engaged with the engagement groove 501 a.

Further, it is possible to prevent engagement failure between the engagement hook 502 and the rotary plate 501 by preventing the end of the engagement claw 502 a from being removed from the side surface 501 aa of the engagement groove 501 a when the engagement claw 502 a of the engagement hook 502 is pulled up. When the headrest main body 4A is tilted backward in a status where the end of the engagement claw 502 a is out of the side surface 501 aa of the engagement groove 501 a, there is a possibility that the engagement between the engagement hook 502 and the rotary plate 501 is disengaged.

The engagement hook 502 is attached to the left hinge part 403 b rockably about a rocking shaft 502 b. That is, the rocking shaft 502 b is provided in the left hinge part 403 b. The engagement hook 502 has the engagement claw (hook) 502 a engaged with the engagement groove 501 a of the rotary plate 501 at its one end. An engagement pin (engagement protruding portion) 502 c engaged with the operation lever 504 is provided in the vicinity (one end) of the engagement claw 502 a. Further, the engagement hook 502 has a biasing spring latch part 502 d, on which the one end of the engagement hook biasing spring 503 is latched, at an end on the other end side provided with the rocking shaft 502 b.

The engagement hook biasing spring 503 is a coil spring. It is provided on the rocking shaft 502 b of the engagement hook 502. The engagement hook biasing spring 503 is latched on the biasing spring latch part 502 d of the engagement hook 502 at its one end. The engagement hook biasing spring is engaged with the edge 403 ba of the left hinge part 403 b at the other end. With this configuration, the engagement hook biasing spring 503 pushes the engagement hook 502 in a direction where the engagement claw 502 a of the engagement hook 502 is engaged with the engagement groove 501 a of the rotary plate 501.

The operation lever 504 has a bent shape, and a rocking shaft 504 b is provided in a bent portion. The rocking shaft 504 b is provided in the left hinge part 403 b. The operation lever 504 has a connecting pin (connecting part) 504 a. The operation strap 410 to release the locking mechanism 500 is connected to one end of the connecting pin. Further, the operation lever 504 has an opening (engagement part) 504 c engaged with the engagement pin 502 c of the engagement hook 502 at its other end. The inner peripheral surface of the engagement part 504 c forms a guide surface to guide the engagement pin 502 c when the operation lever 504 rocks about the rocking shaft 504 b.

The operation lever biasing spring 505 is formed with a coil spring. In the operation lever biasing spring 505, one end is latched on a latch part 403 bb provided at the edge 403 ba of the left hinge part 403 b and the other end is latched on a latch part 504 d of the operation lever 504.

The operation lever biasing spring 505 pushes the operation lever 504 so as to pull up the connecting pin 504 a side of the operation lever 504. With this configuration, in a status where the operation strap 410 is not pulled, the engagement part 504 c of the operation lever 504 is a lowered position. The engagement claw 502 a of the engagement hook 502 is engaged with the engagement groove 501 a of the rotary plate 501.

The left hinge part 403 b is provided with an opening 506 to project the connecting pin 504 a with which the operation strap 410 is connected, to the surface side. The operation lever 504 is pushed with the operation lever biasing spring 505, and the connecting pin 504 a side is pulled up. At this time, the rocking operation of the operation lever 504 is regulated in a position where the connecting pin 504 a is in contact with the upper end of the opening 506.

Here the operation of the locking mechanism 500 will be described. FIG. 5 is a plan view showing the structure of the right hinge part (unlocked state) of the headrest according to the embodiment of the present invention.

In the present embodiment, the operation strap 410 is operated upon release of the locking mechanism 500. That is, the locking mechanism 500 is released by pulling operation of the operation strap 410. By pulling the operation strap 410, the operation lever 504 rocks about the rocking shaft 504 b, and the connecting pin 504 a side of the operation lever 504 is pulled down. Further, when the operation lever 504 rocks, the engagement part 504 c side of the operation lever 504 rises, and the engagement claw 502 a of the engagement hook 502 is guided with a guide surface of the engagement part 504 c and is pulled up. At this time, the engagement hook 502 rocks about the rocking shaft 502 b, and the engagement claw 502 a is pulled out of the engagement groove 501 a of the rotary plate 501.

When the engagement claw 502 a is pulled out of the engagement groove 501 a, the locking mechanism 500 is released. Then the headrest main body 4A becomes tiltable. As the operation strap 410 is not pulled during tilting of the headrest main body 4A, the end surface of the engagement claw 502 a is in contact with the sliding surface 501 b of the rotary plate 501 and slides on the sliding surface 501 b.

The headrest main body 4A is tiled until a side surface 502 aa of the engagement claw 502 a becomes into contact with a side surface 501 ca of the protruding portion 501 c. The side surface 501 ca of the protruding portion 501 c forms a regulation part which regulates the tilting range of the headrest main body 4A.

The side surface 501 aa of the engagement groove 501 a forms a first rotation range regulation part to regulate the rotation range of the headrest main body 4A on the using position side. For this purpose, the side surface 501 a a of the engagement groove 501 a is formed to be higher than the side surface 501 ab. The side surface 501 ca of the protruding portion 501 c forms a second rotation range regulation part to regulate the tilting of the headrest main body 4A on the tilted position side. The engagement groove 501 a is provided in the inside of the rotation range of the first rotation range regulation part 501 aa. The sliding surface 501 b is provided between the engagement groove 501 a and the second rotation range regulation part 501 ca.

FIG. 6 is a plan view showing the structure of the left hinge part (when locked) of the headrest according to the embodiment of the present invention.

A simple stopper mechanism 600 is provided on the back surface of the right hinge part 403 a. The stopper mechanism 600 has a stopper member 601 and a regulation part (regulation pin) 602. Note that in FIG. 6, the position (posture) of the stopper member 601 in a status where the headrest main body 4A is tilted is indicated with a broken line 601 a′.

The stopper member 601 has a stopper piece 601 a and is fixed to the rotary shaft 404. The stopper piece 601 a rocks with respect to the right hinge part 403 a upon tilting of the headrest main body 4A. Otherwise, upon tilting of the headrest main body 4A, the right hinge part 403 a rocks with respect to the stopper piece 601 a.

The rocking of the right hinge part 403 a and the stopper piece 601 a are relative. Actually, as the stopper piece 601 a is on the fixed side, the right hinge part 403 a rocks with respect to the stopper piece 601 a.

The regulation part 602 is fixed to the back surface of the right hinge part 403 a. When the headrest main body 4A is in the using position, a gap is formed between the regulation part 602 and an edge 601 aa of the stopper piece 601 a. The regulation part 602 and the stopper piece 601 a are not in contact with each other. With this configuration, on the locking mechanism 500 side, it is possible to infallibly establish engagement between the engagement claw 502 a of the engagement hook 502 and the engagement groove 501 a of the rotary plate 501.

When a backward impact force acts on the headrest main body 4A and the headrest main body 4A is tilted backward (backward tilting), the regulation part 602 and the stopper piece 601 a come into contact (engaged) with each other. That is, the regulation part 602 is engaged with the stopper member 601 (stopper piece 601 a) when the headrest main body 4A is further tilted backward from the using position, to regulate the backward tilting range of the headrest main body 4A. With this configuration, the backward impact force which acts on the headrest main body 4A is shared with the locking mechanism 500 and the stopper mechanism 600. It is possible to enhance supporting strength for the headrest main body 4A.

In the structure where the headrest main body 4A is supported with the locking mechanism 500 provided at one end of the rotary shaft 404 in the axial direction, when a force acts on the headrest main body 4A, the amount of displacement (offset transformation) on the other end side, in comparison with the one end side provided with the locking mechanism 500, is increased. In the present embodiment, as the stopper mechanism 600 is provided on the other end side, and the stopper mechanism 600 supports the headrest main body 4A on the other end side, it is possible to reduce the offset transformation.

As described above, in the present embodiment, one locking mechanism 500 to lock the tiling of the headrest main body 4A is provided. With this configuration, it is not necessary to synchronize two locking mechanisms and not necessary to attain high part accuracy and high assembly accuracy. When the headrest main body 4A is returned from the forward-tilted position to the using position, it is possible to infallibly lock the headrest main body 4A. Further, in the present embodiment, the simple stopper mechanism 600 to share the impact force is provided. With this configuration, it is possible to stably support the headrest main body 4A in the using position even with respect to a strong impact force.

Further, in the present embodiment, the stopper mechanism 600 plays a role of regulating the tilting of the headrest main body 4A. When the headrest main body 4A is tilted, the stopper piece 601 a becomes in a posture indicated with the broken line 601 a′ with respect to the right hinge part 403 a. At this time, a portion 601 a b (601 ab′) of the stopper piece 601 a (601 a′) comes into contact with the edge 403 a a of the right hinge part 403 a. With this configuration, the tilting of the headrest main body 4A is limited, and the tilting beyond a necessary tilting range is regulated.

That is, the stopper member 601 and the stopper piece 601 a play a role of regulating the tilting of the headrest main body 4A in addition to the role of sharing the backward impact force. With this configuration, in the locking mechanism 500, it is possible to prevent the engagement claw 502 a of the engagement hook 502 from dropping from the protruding portion 501 c of the rotary plate 501.

As described above, when the headrest main body 4A is tilted backward in the status where the end of the engagement claw 502 a is out of the side surface 501 a a of the engagement groove 501 a, there is a possibility that engagement failure occurs between the engagement hook 502 and the rotary plate 501. Otherwise, when the headrest main body 4A is tilted backward in the status where a torsional force acts between the main body frame 401 and the stay 402, and the engagement claw 502 a is out of the engagement groove 501 a in the axial direction of the rocking shaft 502 b, there is a possibility that engagement failure occurs between the engagement hook 502 and the rotary plate 501. However, in the present embodiment, when the headrest main body 4A is tilted backward, as the stopper piece 601 a and the regulation part 602 come into contact with each other, to prevent further backward tilting, it is possible to prevent the engagement failure between the engagement hook 502 and the rotary plate 501.

The stopper mechanism 600 has a more simple structure and the number of parts is smaller in comparison with the locking mechanism 500. Accordingly, it is possible to attain cost reduction and assembly time reduction.

In the present embodiment, a pedestal (mounting portion) 502 e for the engagement hook 502, a pedestal (mounting portion) 504 e for the operation lever 504, and the opening 506 through which the connecting pin 504 a is inserted, are provided on the back surface of the right hinge part 403 a (see FIG. 6). Further, the latch part 403 ab to latch the operation lever biasing spring 505 is provided at the edge 403 aa of the right hinge part 403 a.

The regulation part 602 is removed and the stopper member 601 is replaced with the rotary plate 501. The engagement hook 502 is mounted on the pedestal 502 e, and the operation lever 504 is mounted on the pedestal 504 e. Further, the engagement hook biasing spring 503 and the operation lever biasing spring 505 are mounted. With this configuration, it is possible to exchange the stopper mechanism 600 in the right hinge part 403 a with the locking mechanism 500.

A pedestal (mounting portion) 602 e (see FIG. 4) for the regulation part 602 is provided on the back surface of the left hinge part 403 b. The rotary plate 501 is replaced with the stopper member 601 and the regulation part 602 is mounted on the pedestal 602 e. Further, the engagement hook biasing spring 503 and the operation lever biasing spring 505 are removed, and the engagement hook 502 and the operation lever 504 are removed. With this configuration, it is possible to exchange the locking mechanism 500 in the left hinge part 403 b with the stopper mechanism 600.

In the present embodiment, the right hinge part 403 a and the left hinge part 403 b are provided with the pedestal 502 e for the engagement hook 502, the pedestal 504 e for the operation lever 504, the pedestal 602 e for the regulation part 602, the latch part 403 a b for the operation lever biasing spring 505, and the opening 506 through which the connecting pin 504 a is inserted, in common. With this configuration, it is possible to freely select the locking mechanism 500 and the stopper mechanism 600, and attach them to the right hinge part 403 a and the left hinge part 403 b. In this manner, it is not necessary to individually product the hinge part for the locking mechanism 500 and the hinge part for the stopper mechanism 600, and it is possible to reduce the production cost. Further, it is possible to attain ad-hoc control excess and deficiency of parts.

Note that the locking mechanism 500 has a slight clearance between the engagement claw 502 a of the engagement hook 502 and the engagement groove 501 a of the rotary plate 501. Accordingly, to be precise, the headrest main body 4A slightly rotates with respect to the stay 402 even in the locked state, and offset transformation occurs.

In the status where the headrest main body is locked in the using position, the stopper mechanism 600 has a gap greater than the clearance between the engagement claw 502 a and the engagement groove 501 a, between the stopper piece 601 a and the regulation part 602. Accordingly, offset transformation greater than that on the locking mechanism 500 side occurs on the stopper mechanism 600 side. However, as the stopper piece 601 a and the regulation part 602 are engaged with each other, it is possible to prevent occurrence of further offset transformation.

FIG. 7 is a perspective view showing a mechanism assembly formed by assembling the main body frame, the stay, the hinge parts, the rotary shaft, the connecting part and the biasing member, regarding the headrest according to the embodiment of the present invention.

A mechanism assembly 400 as a skeletal structure of the headrest 4 is formed by assembling the main body frame 401, the stay 402 and the hinge part 403. Note that in FIG. 7, a status where the operation strap 410 is not assembled. The operation strap 410 is connected to the connecting pin (connecting part) 504 a. Further, a frame member 411 to guide the operation strap 410 is provided on the surface (outer surface in the width direction) of the right hinge part 403 b.

FIG. 8 is an exploded perspective view showing the headrest in exploded state according to the embodiment of the present invention.

In the mechanism assembly 400, cushion material 407 a is assembled from the front side, and cushion material 407 b is assembled from the rear side.

As shown in FIG. 8, the operation strap 410 is assembled so as to be inserted through the inside of the frame member 411. The frame member 411 ensures space where the operation strap 410 is provided in the inside of the cushion material. It prevents rubbing between the cushion material and the operation strap 410.

The lower cover (bottom cover) 408 (see FIG. 2) is attached to the assembly of the mechanism part 400, the cushion material 407 a and the cushion material 407 b, from the lower side. The skin 409 covers over the cushion material 407 a and the cushion material 407 b.

Next, the lower cover 408 will be described using FIG. 9 to FIG. 13.

FIG. 9 is a perspective view showing the lower cover.

The lower cover 408 has an opening 408 a, an opening 408 b, a concave portion 408 c 1, and a partition wall 408 d. The lower cover 408 is made of resin.

The opening 408 a is formed at both ends of the lower cover 408 in the width direction of the vehicle seat 1. The operation strap 410 is inserted through the opening 408 a. The operation strap 410 is provided only one side of the headrest 4 in the width direction of the vehicle seat 1. For example, in a left seat, the operation strap 410 is provided on the left side of the headrest 4. In a right seat, the operation strap 410 is provided on the right side of the headrest 4.

In the present embodiment, the opening 408 a is provided at the both ends of the lower cover 408 such that the operation strap 410 may be provided on any side. With this configuration, it is possible to delete the distinction between the lower cover 408 for the right seat headrest 4 and the lower cover 408 for the left seat headrest 4, and to communize the parts.

The right stay part 402 a and the left stay part 402 b are inserted through the opening 408 b. For this purpose, the opening 408 b is provided in spaced two positions in the width direction.

The opening 408 b is provided in inside of the opening 408 a. That is, the opening 408 b is positioned closer to the center of the lower cover 408 with respect to the opening 408 a.

The opening 408 b has a size in the longitudinal direction not so as to interfere with the right stay part 402 a and the left stay part 402 b between the using position and the tilted position of the headrest main body 4A. Further, the size in the width direction is slightly greater than the thickness of the right stay part 402 a and the left stay part 402 b.

The concave portion 408 c 1 is formed between a left opening formation part 408 e 1 where the opening 408 a and the opening 408 b are formed and a right opening formation part 408 e 2, in a shape concaved from the rear side toward the front side. That is, it is formed at the center of the lower cover 408 in the width direction. By providing the concave portion 408 c 1, upon vehicle collision or the like when the rear seat occupant comes into contact with the front seat headrest 4, the possibility of contact between the rear seat occupant and the lower cover 408 is reduced.

The partition wall 408 d is provided around the opening 408 b. In particular, the partition wall 408 d is provided along the edge on the right hinge part 403 a side and the left hinge part 403 b side.

FIG. 10 is a perspective view showing a status where the lower cover is assembled to the mechanism assembly.

The lower cover 408, where the right stay part 402 a and the left stay part 402 b are inserted through the two openings 408 b, is assembled to the headrest 4.

In the present embodiment, a concave portion 408 c 2 is formed on the front side opposite to the concave portion 408 c 1. The concave portion 408 c 2 is formed between the left opening formation part 408 e 1 and the right opening formation part 408 e 2 in a shape concaved from the front side toward the rear side. With this configuration, the lower cover 408 has a shape where the left opening formation part 408 e 1 and the right opening formation part 408 e 2 are connected with a thin connecting part 408 f.

In the present embodiment, the locking mechanism 500 or the stopper mechanism 600 is provided on the side of the respective back surfaces of the right hinge part 403 a and the left hinge part 403 b. Upon tilting of the headrest 4, when the user touches the headrest main body 4, there is a possibility that the user's finger enters the headrest main body 4, to touch the locking mechanism 500 or the stopper mechanism 600.

In the present embodiment, the rotary shaft 404 is provided in a position close to the lower end of the headrest main body 4A. With this configuration, when the headrest main body 4A is tilted, the interference among the stay 402, the cushion material 407, and the skin material 409 is suppressed. However, as the rotary shaft 404 is provided in the vicinity of the lower end of the headrest main body 4A, the movable parts of the locking mechanism 500 and the stopper mechanism 600 are also provided in the vicinity of the lower end of the headrest main body 4A. In this case, the user's finger easily reaches the locking mechanism 500 and the stopper mechanism 600.

FIG. 13 is a perspective view of the headrest as a comparative example with respect to the present invention viewed from the lower surface side.

In the comparative example, the difference from the present embodiment is that the lower cover 408 is not provided. The configuration where the cushion material 407 directly covers the mechanism assembly 400, and further, the skin 409 covers over the cushion material is the same as that of the present embodiment.

When the lower cover 408 is not provided, a large opening occurs on the periphery of the right stay part 402 a and the left stay part 402 b. The finger inserted from this opening may easily reach the locking mechanism 500 and the stopper mechanism 600 formed in the hinge part 403.

In the present embodiment, in the configuration where the cushion material 407 directly covers the mechanism assembly 400, and further, the skin 409 covers the cushion material, the resin lower cover 408 covers only the lower part of the headrest main body 4A. In this case, the lower cover 408 covers the vicinity of the hinge part 403, leaving a minimum opening around the right stay part 402 a and the left stay part 402 b. With this configuration, it is possible to prevent the user's finger from erroneously touching the locking mechanism 500 and the stopper mechanism 600.

Further, the cushion material 407 directly covers the mechanism assembly 400. A cover part of resin or the like to cover the mechanism assembly 400 is not provided. Accordingly, it is possible to reduce the number of parts, and downsize the headrest.

As the partition wall 408 d is provided along the edge of the opening 408 b on the hinge part 403 side, it prevents the user's finger from erroneously touching the locking mechanism 500 and the stopper mechanism 600.

In the present embodiment, the rotary plate 501 and the stopper piece 601 a of the stopper member 601 are in contact with the edge 403 a a of the right hinge part 403 a and the edge 403 b a of the left hinge part 403 b. The partition wall 408 d infallibly prevents insertion between the rotary plate 501 and the stopper piece 601 a, and between the edge 403 a a of the right hinge part 403 a and the edge 403 b a of the left hinge part 403 b.

FIG. 11 is a perspective view of the left hinge part viewed from the front side. FIG. 11 shows an XI part in FIG. 10 viewed from another angle.

The operation strap 410 is connected to the connecting pin 504 a. Further, the operation strap 410 is inserted through the opening 408 a of the lower cover 408. When the user pulls the operation strap 410 in an arrow direction in the figure, the user can infallibly pull down the connecting part of the operation strap 410 connected to the connecting pin 504 a. With this configuration, the connecting pin 504 a is pulled down downward in the opening 506, and the operation lever 504 is correctly operated.

That is, the connecting pin 504 a smoothly operates by application of an operation force in a circumferential direction about the rocking shaft 504 b with respect to the connecting pin 504 a of the operation lever 504. Even when an operation force from the connecting pin 504 a toward the rocking shaft 504 b or an operation force toward the opposite direction is acted on the connecting pin 504 a, the connecting pin 504 a does not smoothly operate.

In the present embodiment, it is possible to apply an operation force in the circumferential direction about the rocking shaft 504 b with respect to the connecting pin 504 a by operating the operation strap 410 in its length direction. The opening 408 a of the lower cover 408 guides the operation strap 410 such that the operation force by the operation strap 410 acts in the circumferential direction about the rocking shaft 504 b with respect to the connecting pin 504 a between the opening 408 a and the connecting pin 504 a.

In this manner, as the opening 408 a is provided, the lower cover 408 also functions as a guide member to guide the operation strap 410 in a correct operation direction.

FIG. 12 is a cross-sectional view showing an assembled status of the lower cover and the skin material.

The skin 409 covers the cushion material 407, and a hook 409A sewn at a lower end is latched through the opening 408 a on the lower cover 408. In this manner, the lower cover 408 also serves as a latch part member for the skin 409.

REFERENCE SIGNS LIST

-   1 . . . vehicle seat, -   2 . . . seat cushion, -   3 . . . seat back, -   4 . . . headrest, -   4A . . . headrest main body, -   401 . . . main body frame, -   401 a . . . right frame part, -   401 b . . . left frame part, -   401 c . . . connecting frame part, -   401 d . . . main body frame extension part, -   402 . . . stay, -   402 a . . . right stay part, -   402 b . . . left stay part, -   402 c . . . connecting stay part, -   403 . . . hinge part, -   403 a . . . right hinge part, -   403 aa . . . edge of right hinge part, -   403 ab . . . latch part, -   403 b . . . left hinge part, -   403 ba . . . edge of left hinge part, -   403 e . . . bent portion of respective stay part, -   404 . . . rotary shaft (tiltable shaft), -   405 . . . connecting part, -   405 a . . . right connecting part, -   405 b . . . left connecting part, -   406 . . . biasing member, -   407 . . . cushion material, -   408 . . . lower cover (bottom cover), -   408 a . . . opening, -   408 b . . . opening 408 b, -   408 c . . . concave portion, -   408 c 1 . . . concave portion, -   408 c 2 . . . concave portion, -   408 d . . . partition wall, -   408 e 1 . . . left opening formation part, -   408 e 2 . . . right opening formation part, -   408 f . . . connecting part, -   409 . . . skin, -   410 . . . operation strap, -   411 . . . frame member, -   500 . . . locking mechanism, -   501 . . . rotary plate, -   501 a . . . engagement groove, -   501 aa, 501 ab . . . side surface of engagement groove 501 a, -   501 b . . . sliding surface, -   501 c . . . protruding portion, -   502 . . . engagement hook, -   502 a . . . engagement claw, -   502 b . . . rocking shaft, -   502 c . . . engagement pin (engagement protruding portion), -   502 d . . . biasing spring latch part, -   502 e . . . pedestal for engagement hook, -   503 . . . engagement hook biasing spring, -   504 . . . operation lever, -   504 a . . . connecting pin (connecting part), -   504 b . . . rocking shaft, -   504 c . . . engagement part, -   504 d . . . latch part, -   504 e . . . pedestal for operation lever, -   505 . . . operation lever biasing spring, -   506 . . . opening connecting pin 504 a is inserted through, -   601 . . . stopper member, -   601 a . . . stopper piece, -   601 aa . . . edge of stopper piece 601 a, -   602 . . . regulation part (regulation pin). 

The invention claimed is:
 1. A vehicle seat headrest comprising: a stay held on the seat back side; and a headrest main body supported forward rotatably from a using position with respect to the stay, wherein the headrest main body has: a main body frame forming a strength member; a hinge part which connects the main body frame rotatably with respect to the stay; a locking mechanism which fixes the main body frame in the using position with respect to the stay; and cushion material which covers the main body frame and the hinge part, wherein a resin lower cover, having an opening through which the stay is inserted, covers a lower surface of the headrest main body, wherein the stay has: a right stay part extended downward from the right side of the headrest main body; and a left stay part extended downward from the left side of the headrest main body, wherein the lower cover has: a right opening formation part having a first opening through which the right stay part is inserted; and a left opening formation part having a second opening through which the left stay part is inserted, wherein the hinge part has: a right hinge part provided on the right side of the main body frame; and a left hinge part provided on the left side of the main body frame, wherein the locking mechanism is formed in at least one of the right hinge part and the left hinge part, wherein the lower cover has a concave portion formed forward from the rear side in a connecting part which connects the right opening formation part to the left opening formation part, wherein the lower cover has a third opening, through which an operation strap for releasing operation for the locking mechanism is inserted, in at least one of the right opening formation part and the left opening formation part, and wherein the third opening is provided on the outside with respect to the first opening or the second opening.
 2. The vehicle seat headrest according to claim 1, further comprising skin material that covers the cushion material, wherein a lower end of the skin material is latched on the third opening.
 3. The vehicle seat headrest according to claim 2, wherein the locking mechanism is provided in one of the right hinge part and the left hinge part, while the stopper mechanism is provided in the other one of the right hinge part and the left hinge part, and wherein the stopper mechanism is not engaged with a regulation part in the using position, but is engaged with the regulation part when the headrest main body is tilted backward from the using position, to regulate backward tilting of the headrest main body.
 4. The vehicle seat headrest according to claim 3, further comprising a rotary shaft fixed to the stay and rotatably connected to the right hinge part and the left hinge part, wherein the rotary shaft is positioned below a connecting stay which connects the right stay part to the left stay part.
 5. The vehicle seat headrest according to claim 4, wherein the locking mechanism has: an engagement hook which has an engagement claw and which rocks about a first rocking shaft; and a rotary plate which has an engagement groove engaged with the engagement claw and which rotates about the rotary shaft, and wherein the stopper mechanism has: a stopper member having a stopper piece which rocks about a second rocking shaft; and a rocking range regulation part which regulates a rocking range of the stopper piece by engagement with the stopper piece.
 6. The vehicle seat headrest according to claim 5, wherein the lower cover has the third opening in one of the right opening formation part and the left opening formation part, and a fourth opening in the other one of the right opening formation part and the left opening formation part. 